Process of making metallic alloys.



H. ELDRIDGE.

PROCESS OF MAKING METALLIC ALLOYS.

APPLICATION FILED DEC.22. I916.

1,246,571. Patented N0v.13, 1917.

HILLIABY ELD'RIDGE,

on NEW Yonx, 1v. Y.

PROCESS OF MAKING METALLIC ALLOYS.

Specification of Letters Patent.

Patented Nov. 13, 1917.

Continuation of application Serial No. 83,751, filed March 13, 1916. This application filed December 22, 19 1. Serial No. 138,362.

To all whom it may concern:

Be it known that I, HILLIARY Emamon, a citizen of the United-States, residing at 6&5 Eighth avenue, New York, count of New York, and State of New York, ave invented certain new and useful Improvements in Processes of Making Metallic Alloys, fully described and represented in the following specification and the accompanying drawings, forming a part of the same.

The present invention consists of a .process for making alloysof metal by heating the less fusible metal to an alloying temperature, and subjecting such heated metal to the vapor of a more fusiblemetal and effecting a complete union of the metals in a molten state.

This application is a continuation of my application N 0. 83,751 filed March 13, 1916,

and allowed August 16, 1916, being a sub-- stitute therefor, and claims the same subject-matter as that allowed application.

Such alloys can be formed at a temperature below the melting temperature of the less fusible metal, and the process can therefore be effected by heating the less fusible metal to an alloying temperature without melting it, or it may be effected by melting the less fusible metal.

The process is especially applicable to the manufacture of any alloy of copper with such metals as zinc, antimony, lead, tin, or other volatile metals which melt and volatilize at a relatively low temperature, and are therefore liable to material loss by volatilization if the alloying metal be melted with the copper in an open vessel.

In this process, the vapor of the alloyin metal is brought into direct contact wit% the heated copper and isabsorbed by the copper whether in a melted state or merely heated to a suitable temperature, the alloy thus formed running ofi from the surface of the copper, if solid, and exposing a new surface to a continuation of the same action.

If the copper be melted, the vapor of the alloying metal may be blown or forced through the melted copper, to be absorbed by the copper, if the mass of the metals be considerable.

The use of the vapor effects a more thorough and gradual formation of the alloy than the mere melting of the metals together.

' all the ingredients,

One great advantage of the invention is ceptacle containing the metal thereby maintaining a reducing atmosphere which has the further effect of purifying the alloy by reducing such oxids as it may contain.

The zinc vapor can be derived from any ore of zinc which with a suitable reagent may, under the influence of heat, be reduced to an oxid of the metal; as for example, a sulfate, 3. carbonate, &c. The use of such an ore or oxid of zinc is much less costly than the use of metallic zinc.

In the drawing, Figure l is a diagram in vertical section of a furnace for heating a crucible; and Fig. 2 is a diagram in vertical section of a furnace with two connecting chambers.

An apparatus is shown in the annexed drawing for heatin a crucible containing her A with a crucible B therein having a cover C, all these parts being shown in section. A layer D is shown in the bottom of the crucible representing zinc oxid or ore mixed with or coveredby charcoal E, to act as the reducing agent. ,The mineral or carbon is preferably reduced to adivided state.

ingots of copper -F are shown resting upon the charcoal E, and when the crucible is heated to the proper temperature the charcoal combining with the oxygen of the zinc oxid generates carbon-monoxid (CO),

aving a flirnace-chamwhich is partly retained in'the crucible by the cover 0, and forms a reducing atmosphere therein which protects the alloy that is formed by the absorption of the vapor.

Burner-inlets J are shown inthe walls of the furnace,-and burners would be provided to heat the chamber.

The heat is regulated to volatilize thecopper, and the vapor .of the zinc is thus brought into contact with the "heated sure face of the copper ingots. The copper while thus heated absorbs the zinc vapor, which combines with the copper to form a film of brass alloy upon the surface of the copper;

the temperature in the crucible being sufficient to melt this alloy so that it runs off and accumulates in the bottom of the crucible.

The process of absorption is continuous, as the zinc vapor attacks the surface of the copper where it is exposed by the running off of the alloy, and the formation of such alloy upon the surface of the copper continues as long as the zinc vapor is supplied, with the effect of converting thecopper and zinc vapor into the alloy desired.

The proportions of the two metals in the alloy depends upon the proportions placed in the crucible, as the zinc vapor is almost wholly utilized by union with the copper.

It will be understood from the above description that the operation practised with the ingredients all in one crucible does not consist in merely meltin the ingredients together, or subjecting t em to the melting temperature of copper but that the tom perature is intentionally maintained below that of melted copper, so as to economize in the fuel and prevent any difiusion or loss of the zinc vapor. When heating allthe ingredients in one crucible the copper is separated from the zinc oxid or ore, and is kept apart from the alloy, as formed, so as to maintain a continuous exposure of the coppers surface to the zinc vapor.

tap-hole g being c osed during the alloying operation, and the copper being heated in the chamber a"to an alloying temperature while the zinc is heated in the chamber a to a vaporizing temperature, so that its vapor passes through the passage 03 into the chamber a, where it is absorbed by the copper.

Inlets h are shown over the chambers to insert the metal thereat, such inlets being closed by covers 0 provided with liftingbails d. A spout f is shown connected with the tap-hole g, by which the alloy may be withdrawn from the furnace at the close of the alloying operation.

From the above description it will be understood that the more fusible metal may be va orized in any convenient manner, so as to absorbed by the less fusible 'metal heatedto a suitable temperature.

My invention does not consist in the mer melting of zinc and copper together,.or the mere heating of zinc ore and copper to form an alloy, but consists in subjecting the copper to the vapor of the alloying metal and producing a molten alloy of the two metals. v

This invention permits the copper to be alloyed with the more fusible metal without melting the copper, and also in one form of the invention it permits the melting of the copper in one chamber or furnace and the vaporizing of the zinc in another chamber or-furnace, as stated above, and conducting the vapor into the chamber where the copper is heated, to form the alloy therein.

Where the zinc and copper are heated in the same receptacle, the copper is carefully separated from the zinc ore'to prevent its immersion in the molten alloy, which would prevent the access of the vapor to the surface of the copper, and the continuous formation of the alloy in a molten state, as desired.

This separation is efiected by placing the alloying element in the bottom of the receptacle and placing a layer of porous materiallike the charcoal E upon the top of 1 the said element, thus supporting the copper above the level of the alloy.

After the charcoal is consumed. the copper is prevented from contact with the molten alloy by the layer of earthy material, which remains after the zinc is extracted from the ore. Such earthy material prevents immersion of the copper in the alloy during the formation of the latter, The surface of the copper is thus exposed continuously during the alloying operation to the vapor of the zinc.

What I do claim as my invention, and desire to secure by Letters Patent is:

1. The process of alloying copper with a more fusible metal, as zinc, lead, &c., which consists in heating the copper and the alloying metal free from contact with one another, the copper being heated to an alloying temperature and the zinc to at least a vaporizing temperature, and subjecting the copper thus heated to the vapor of the zinc until the desired alloy is formed in a molten state;

2. The process of alloying copper with more fusible metals as zinc, lead, &c.-, which consists in heating the copper in one chamber or receptacle to an alloying temperature, vaporizing the alloying metal in another chamber, and conveying the said vapor into contact with the heated copper and formsis ing an alloy of the said metals in a molten por into contact with the melted copper and forming an alloy of the said metals in a regenerating a vapor of the alloying metal, molten state. conveying the said vapor into contact'with 4. The process of alloying copper with the molten copper, and forming an alloy of 10 more fusible metals as zinc, lead, &c., which the said metals in a molten state. 5 consists in meltingthe copper in one re- In testimony whereof I have hereunto set ceptacle, reducing an oxid or me of the al-' my hand. loying metal in a separate chamber and HILLIARY ELDRIDGE. 

